How a Roll Forming Machine is Used to Produce Rack P Step Beams for Warehouse Pallet Racking Systems

How a Roll Forming Machine is Used to Produce Rack P Step Beams for Warehouse Pallet Racking Systems

Rack beams roll forming machine is used to produce rack P step beams (also known as cross beams) for warehouse pallet racking system. Rack beams provide the structural support that ensure the pallet racking system can hold the weight of the materials stored without bowing or creating an unsafe condition.

Upright Rack

The uprights of pallet racks are the vertical towers that connect beams to create storage rows. They come in a variety of heights and widths to suit the storage space you have available. Each upright has a number of holes in it, and these holes are the key to connecting the beams that form the shelves. These holes can take different forms, including rhomboid, butterfly, and gourd holes.

Uprights can be either roll-formed or structural. pallet rack roll forming machine The main difference between these two types has to do with the steel used to make them. Structural pallet racks are made from thicker, stronger steel than roll-formed uprights. They are also generally more durable and can withstand a greater load capacity than their roll-formed counterparts.

These uprights have a slant-back design that helps minimize damage from forklifts. It also makes it easier for forklifts to maneuver in the racking system. The slant-back design also helps to reduce the amount of space needed to store pallets, as well as provide more flexibility for storage of non-palletized unit loads.

Uprights can be equipped with various styles of hole punches to accommodate a wide range of attachments. Some common types of punches include teardrop, rectangle t-bolted, round hole hex head bolted, round corner slotted with steel clips, and louvered. Most of these punch styles are compatible with each other, but the most common is the teardrop style.

Step Beam

Step beams are one of the key components in metal racking systems installed in warehouses. They are horizontal profiles that serve to support pallets and their loads, distributing the weight evenly across the entire racking structure. Racking beams are part of a larger structure that also includes frames (vertical elements that are formed by two or more uprights), shims to level uneven flooring and anchor bolts to secure the racking system to the concrete slab.

Structural racking systems are typically constructed of heavier, thicker-gauge steel and offer a much higher storage capacity. However, the longer lead times, skilled labor and precise engineering associated with these types of systems come at a premium in terms of cost. This is especially true when you need to modify a structural racking system, adjust beam levels or replace parts.

Alternatively, roll-formed selective pallet racking systems are often constructed of lighter, thinner-gauge steel. These systems are best suited for facilities that store changing products of varying sizes in a high-volume, fast-paced environment. Unlike structural racking, which is bolted together, the standardized components of roll-formed selective pallet racking systems can easily be adjusted or disassembled for situations where you might need to change beam levels or replace a damaged component. This type of racking system can be constructed using either step or box beams.


The bracing, also known as struts, are additional structural components located between the uprights that give extra support for heavy loads. They are made of either steel bars or angle sections and may be notched and cut to length or cold-formed. These supports help prevent column buckling, which can occur when a rack component’s load causes a large deflection perpendicular to the axis of the element, exceeding the element’s compressive yield strength.

Cantilever racks are a type of storage racking with horizontal arms that support long or cumbersome items like lumber, pipe and carpet rolls. They are usually installed on a raised floor or on a concrete slab and are accessed by forklifts that extend their arm into the system. Although these systems provide useful and high-density storage, they are susceptible to damage from forklifts.

Whether you’re building a new racking system or replacing damaged components, standard rack dimensions and measurements are critical. This information helps you determine the rated load capacity and ensures your racking system can handle the intended weight without compromising safety or structural integrity.

A plaque that communicates the rated load pallet rack roll forming machine capacity of a racking bay. These plaques should include a beam’s maximum load capacity, the system’s overall capacity and any other relevant information that can help you understand your racking system’s limitations.

Racing Rack

A racing rack is a bar-shaped gear that can be meshed with a pinion to convert rotational motion into linear movement. It is made from 7075 aluminum and is often hard anodized. This treatment helps prevent corrosion and extends the life of the rack. This is especially useful when used in harsh environments. It is also useful in work escapement mechanisms.

Roll forming machines create specific configurations out of long strips of metal, most commonly coiled steel. Typically, the strip is passed through a series of stations where fixed rollers both guide the strip and bend it. Each successive set of rollers bends the metal a little more, which allows the machine to fabricate a part that matches the desired cross-section profile.

The benefit of a rack constructed using this method is that it is quick to construct and easy to adjust, which makes it ideal for warehouses with frequent changes in inventory and limited storage space. However, it can be prone to damage and may not provide enough structural support for heavier loads. In these situations, a structural rack system is preferred.

Structural racking is built out of thicker, more rugged hot-rolled channel and angle sections. It requires more of an investment than a roll form system, but many customers find the additional cost offset by the increased durability and lifespan of this type of construction.

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